Mold for making cellular cores for radiators



5 Sheets-Sheet l .DEDDD C. A. HAMMOND y MOLD FOR MAKING CELLULAR Comas FOR RADIATORS Filed oct. 2a, 1959 fgl LEDDDEDD DEEDD.

June 24, 1941.

LL. L

.Ummmmnmmmnmmmmmmmmf u mmmmmmmmmmmmmmmm C. A. HAMMOND Junel24, 1941.

" MOLD FOR MAING CELLULAR CORES FOR RADIATQRS Filed Oct. 28. 1959 3 Sheets-Sheet 2 mi H wv I- 27' .5 a 427 l2.9 )55% y l f L 30 47 fa aff June 24, 1941.

c. A. HAMMOND MOLD FOR MAKING CELLULAR CORES FOR RADIATQRS ,Filed 001;. 28, 1939 3 Sheets-Shset 3 m w a W SUWL L M mmmmmmm mmmmmmmmw mmmmmmmm mmmmmmmm mmmmmmm mmmmmmmmf@ mmmmmmmm mmmmmmmm Dmmmmmmm Emmmmmmm DEELDDDE@ Patented June 24, 1941 UNITED STATES PATENT orFlcE MOLD Fon MAKING CELLULAR cortas Fon. RADIAToRs Charles A. Hammond, Alden, N. Y. Applieatitn october 2s, 1939, serial No. 301,826

(o1. ca 151) 9 Claims.

This invention relates to a cellular core for radiators or heat exchangers and a method and mold for making the same.

In its completed form this core comprises a body of cast metal, preferably aluminum, which is provided with a plurality of air passages and a plurality of liquid passages interposed between said air passages, said body being made integrally and without any joints between the walls of the air passages and the liquid passages.

It is the object of this invention to provide a mold and method of making said heat exchanger core economically and expeditiously and, in a manner resulting in a product which isv strong and durable` and not liable to leak even when subjected to severe usage.

A heat exchanger core made in accordance with this invention .is more particularly intended as a part of a radiator forl cooling the water which is circulated in a gas engine for reducing the temperature of the same although the heat exchanger may also be used for various other purposes.

This application is a continuation-impart of an application led by myself August 12, 1938 and serially numbered 224,592.

In the accompanying drawings: l

Fig. 1 is a front elevation of a heat exchanger core made in accordance with this invention.

Figf2 is a fragmentary horizontal section, on an enlarged scale, taken on line 2 2, Fig. 1.

Figs. 3 and 4 are fragmentary vertical sections, on an enlarged scale, taken on lines 3-l-3 and 4-4, Fig. 1, respectively. y

Fig. 5 is a top plan view of the mold for making the heat exchanger core shown in Figs. 1-4.

Fig. 6 is a transverse section of the same taken on line (5 6, Fig. 5.

Fig. 7 is a longitudinal section taken on line 1 -1. Fig. 5.

Fig. 8 is a fragmentary perspective View of two interlocking core plates for producing two liquid passages at right angles to each other in the core.

Fig. 9 is a fragmentary perspective view of the core shown in Figs. 1-4.

Fig. 10 is an enlarged top plan view showing the manner in which the adjacent ends of an outer longitudinal wall and an outer transverse wall of the mold are interlocked.

Fig. 11 is a fragmentary sectional elevation of a core of modied form made in Iaccordancev with this invention. f,

Fig. 12 is a fragmentary top planl View of a mold embodying this invention for making the core shown in Fig. 11.

In the following description similar characters of reference indicate like parts in the several figures of the drawings.

The core for heat exchangers shown in Figs. 1-4 and 9 is more particularly intended for a radiator for reducing the temperature of the cooling water of gas engines by dividing this water into a plurality of streams and subjecting the same to the cooling action of a plurality of streams of air which carry the heat away from the water. As shown in these figures the core is constructed as follows:

The body of the core is provided with a plurality of air passagesor tubes Eil which are arranged to form horizontal and vertical rows and extend horizontally from the front side of 'the core to the rear side of the same, a plurality of vertical water channels or conduits 2| alter* hating with the vertical rows of water passages, and ai plurality of horizontal or transverse water channels or conduits 22 alternating with the horizontal rows of air passages and intersecting the vertical water channels so as to communicate therewith Vand thus provide for cross circulation as well as vertical circulation of the water through the core.

VEach of the air passages is preferably of rectangular form in cross section and enclosed on its vertical sides by vertical walls 23, and on its horizontal sides by horizontal walls 24. The vertical walls of adjacent vertical rows of air passages form the vertical walls or partitions of the respective Vertical` water `or liquid channel between them and the horizontal walls of the adjacent horzontal rows of air passages form the horizontal walls or partitions of the horizontal water or liquid channels.,

The front and rear longitudinal sides of the longitudinal water channels are closed by side walls 25 and the front and rear longitudinal sides of the transverse water channels are closed by side walls 26. 'lhe horizontal water channels are closed at their opposite ends by lling pieces Il, as shown in Fig. 9, but the lower and upper ends of the vertical water channels communicate respectively with lower and upper water headers or boxes It. ISI` forming parts of the conduit whereby Water is circulated through the heat exchanger and the jacket of the engine for the purpose of cooling the water which comes from the engine by transferring the heat to the air and then returning the water at a lower temperature to the water jacket of the engine.

The mold for making the radiator or heat eX- changer core'shown in Figs. 1-4 is preferably constructed as follows:

Referring to Figs. 5-8, the numeral 2'! represents a bottom plate of metal which is preferably of rectangular form. On the margin of the bottom plate is mounted a rectangular flooding wall 23 which is adapted to enclose the mold on its sides and confine a body of cooling Water or liquid around the mold and the casting therein if it is desired to reduce the temperature of the casting and the mold rapidly after the casting operation. This flooding wall is preferably detachably mounted on the bottom plate by providing the lower edge of this wall with recessed flanges 23 which fit over the edges of the bottom plate and hold the same against horizontal movement thereon but permit the flooding wall to be easily removed from the bottom plate and reapplied thereto.

From the upper side of the bottom plate a plurality of core posts project upwardly, each of which is adapted to form one of the air passages of the heat exchanger core and is of corresponding shape in cross section. Each of these posts is made separate from the bottom plate and held in its proper position thereon by a square dowel 3| arranged at the lower end of the respective post and engaging with a correspondingly shaped socket 32 in the upper side of the bottom plate, 1'

and a screw 33 connecting the lower end of the post with the bottom plate, as shown in Figs. 5, 6 and '7. In order to permit the cast heat exchanger core to be easily lifted from the posts of the mold each of these posts is made of upwardly tapering shape, as shown in Figs. 5 and 6.

The outermost walls of the air passages of the cast heat exchanger core are preferably formed by two outer longitudinal mold walls 34 normally arranged vertically and lengthwise along the outer longitudinal sides of the outer longitudinal rows of posts and two outer transverse mold walls 35 normally arranged vertically and transversely along the outer transverse sides of the outer transverse rows of posts. These mold walls are made of suitable metal and are movable relative to the bottom plate and posts so as to permit of readily opening the mold for removing the cast core therefrom and reassembled for making another casting. For this purpose the longitudinal mold walls are pivotally connected at their lower edges with the bottom plate by means of hinges 36 whereby these walls, when free, can be swung laterally from an upright operative position to a horizontal inoperative position for convenience in removing the casting from the mold.

Each of the transverse mold walls is adapted to be interlocked at its opposite ends with the corresponding ends of the longitudinal mold walls so as to complete the sides of the mold cavity and also hold these walls in their operative position. This is preferably accomplished by providing the opposite ends of each longitudinal mold wall with an inwardly projecting locking iiange 31 and providing each end of each transverse mold wall on its outer side with a hook 38 which slidingly embraces the locking flange on the adjacent end of the respective longitudinal mold wall, as shown in Fig. 10, thereby holding both of these walls in an upright position. If it is desired to open the mold preparatory to releasing the core casting, the transverse mold walls are iirst slipped upwardly out of engagement from the locking flanges of the longitudinal mold walls, after which the latter can be swung laterally outward. Reassembling of these walls may be effected in a manner reverse of that just described. When the mold side walls 34, 35 are in their upright operative position the same are spaced lengthwise, respectively, from the outermost longitudinal and transverse rows of posts so as to form mold cavities between the inner sides of these walls and the outer sides of these posts which receive the metal forming the outer walls of the several air passages in the cast body of the radiator or heat exchanger.

Within each of the lanes or spaces between the adjacent longitudinal rows and the transverse rows of core posts are arranged removable core bars which are adapted to form the longitudinal an-d transverse water channels between the air passages or tubes of the heat exchanger or radiator which core bars are constructed and mounted relative to each other and the mold walls as follows:

The numerals 39, 40 represent the two sections of each of the transverse core bars which have the form of flat strips of metal arranged side by side in the same plane and having their opposing inner longitudinal edges 4|, 42 inclining in opposite directions and normally engaging each other while their outer longitudinal edges 43, 44 are parallel and the transverse narrow and wide opposite ends 45, 46 of each core bar section are in line, respectively, with the corre'- sponding wide and narrow transverse opposite ends of the companion core bar section, and thus form a complete core bar which is of rectangular shape as a whole, as shown in Figs. 6 and 8. Each of these transverse core bars is equal in width to the proposed width of the transverse water channels in the heat exchanger and held centrally in the respective lane in the mold by engaging its opposite end edges with t vertical retaining grooves 47 in the inner sides of the longitudinal mold walls of the mold, as shown in Fig. 5, and the same is also limited in its downward movement in the respective lane by engaging the lower edge of the respective mold bar with shoulders 48 on the longitudinal mold walls, as shown in Fig. 6, thereby forming a space or mold cavity between this lower edge of the respective transverse mold bar and the upper side of the bottom plate into which the metal is poured to form the front longitudinal side wall 25 of the respective transverse water channel. The upper longitudinal edges of the transverse core bars terminate a short distance below the upper ends of the core posts and the mold side walls so that suiicient metal may be poured into the mold cavity to cover the upper edges of the transverse core bars to form the rear side walls 25 of the transverse water channels without running over the outer mold walls.

The numerals 49, 94 represent the two sections of each of the longitudinal core bars which also have the form of flat metal strips normally arranged side by side in the same plane and having their opposing inner longitudinal edges 5l), 5| inclined in opposite directions and engaged with each other While their outer longitudinal edges 52, 53 are parallel and the transverse narrow and Wide opposite ends 54, 55 of each of these bar sections are in line, respectively, with the corresponding wide and narrow transverse opposite ends of the companion longitudinal core bar section. The opposite ends of each of the longitudinal core bars engage slidingly with upright retaining grooves 56 0n the inner sides of the transverse mold Walls, as shown in Figs. 5 and '7,

and the seotions of each of `these:longitudinal core bars pass through correspondingslotstl in the sections of the several transverse core bars, as shown in Figs. 6, 7 and 8, thereby causing the transverse and longitudinal core1bars to intersect and interlock and form .theintercommunieating longitudinal and transverse `waterchannels in the body oi the heat exchanger which is cast in the mold.

After the several mold membershave been assembled in the manner described molten metal,

such as aluminum, ispoured into the mold so as to fill the spaces or cavities therein from the bottom to alevel vslightly above ,theupper Vedges of the transverse mold bars. Cooling of` the'rnetal may now be effected solely under atmospheric Conditions but may be expedited, if desired, by subjecting the mold and casting to an air blast, or water may be poured into the mat58 which is formed around the mold by the flooding wall 28. After the mold and casting have been cooled and the casting has hardened the ilooding wall Ais removed to release the mold vcooling water. and then the transverse mold walls are withdrawn upwardly from the longitudinal mold walls and the latter are turned laterally outward, thereby freeing these walls from the casting. The longitudinal core bars are now removed from the casting and the transverse mold bars by pulling the two sections of each longitudinal core bar outwardly from opposite sides of the casting with the wide end of each of these sections in advance, during which operation the draft provided on these `sections by their opposing inclined edges frees these sections from each other and permits such removal to be effected `easily and conveniently. Thereafter the transverse mold `,bars are Withdrawn from the casting and` the latter lifted from the bottom plate and core posts ready for any other finishing operation whichmaybe desired preparatory to assembling the same with the lower and upper headers of'theradiator or other equipment.

When horizontal or transverse waterV channels or conduits are formed inthe cellular core, `'the outer ends of these channels 22 are closed by the lling pieces Il which may be secured in place in any suitable manner.

If desired, broaches may be drawn through the air passages after the casting operation so that the thickness of the walls of the air passages is uniform and the amount of metal used is reduced to a minimum.

If it is desired to make a cellular core for radiators or heat exchangers in which the horizontal water channels are omitted and only employ vertical water channels, as shown in Fig. 11, this can be accomplished by constructing the mold as shown in Fig, 12.

In this form of cellular core the air passages or tubes 59 are arranged in vertical rows and the passages or tubes in each row are separated from each other by partitions B0, and a vertical water passage 6l is formed between adjacent vertical rows of air tubes or passages, whereby transference of heat from the water to the air only occurs through the vertical walls 62 which separate the air passages from the water channels.

The mold for producing the cellular core shown in Fig. 11 may be constructed as shown in Fig. 12 in which the transverse core bars are omitted and the core posts 63 are arranged closer to each other in .a direction lengthwise of the mold and only longitudinal core bars E4 are employed between adjacent vertical rows of core posts. In

other respects the mold shown in Fig. l2 is substantially like that shown in Fig. 5, as well as the manner of assembling and disassembling the parts of the mold during the operation of making cellular cores of the character shown in Fig. 11.

Inasmuch as the cellular core shown in Fig. l1 is made in one piece and the form shown in Figs. 1-4 and 9 is made in one piece with the exception of the llers Il, a cellular core made in accordance with this invention is not liable to leak and therefore can be produced at low cost and entail little, if any, expense for maintenance.

.The molds used in the manufacture of these cellular cores are also very simple in construction, easy to handle and not liable to be damaged in use, thereby enabling the cellular cores to be made expeditiously and economically.

I claim as Vmy invention:

, `l. 1A mold for casting of metal the body of a cellular core for heat exchangers having a plurality of air tubes and a plurality of water channels arranged between adjacent rows of air tubes, said mold comprising a bottom plate adapted to form one` side of the cast cellular core, a plurality ogf core posts for forming said tubes projecting upwardly from said bottom plate and arranged in rows, and core bars normally arranged in the lanes between adjacent rows of said posts to form said channels and adapted to be moved lengthwise from the casting.

2. A mold forcasting of metal the body of a cellular core for heat exchangers having a plurality of air tubes and a plurality of water channels arranged between adjacent rows of air tubes,

. said mold comprising a bottom plate adapted to form one side of the cast cellular core, a plurality of core posts for forming said tubes projectingyupwardly from said `bottom plate and arranged in rows, and Icore bars normally arranged in the lanes between adjacent rows of said posts to form said channels and adapted to be moved lengthwise from. the casting and each of said core bars comprising two sections which have their adjacent longitudinal edges engaging with each other and inclined in opposite directions.

3. A mold for casting of metal the body of a cellular core for heat exchangers having a plurality of air tubes and a plurality of water channels arranged between adjacent rows of air tubes, said mold comprising a bottom plate adapted to form one side of the cast cellular core, a plurality of core posts for forming said tubes projecting upwardly from said bottom plate and arranged in rows, core bars normally arranged in the lanes between adjacent rows of said posts to form said channels and adapted to be moved lengthwise from the casting, and mold walls mounted on said bottom plate around said posts and provided on their inner sides with re- Vtaining grooves which receive the ends of said core bars.

4. A mold for casting of metal the body of a cellular core for heat exchangers having a plurality of air tubes and a plurality of water channels arranged between adjacent rows of air tubes, said mold comprising a bottom plate adapted to form one side of the cast cellular core, a plurality of core posts for forming said tubes projecting upwardly from said bottom plate and arranged in rows, core bars normally arranged in the lanes between adjacent rows of said posts to form said channels and adapted to be moved lengthwise from the casting, mold walls mounted on said bottom plate around said -posts and provided on their inner sides with retaining grooves which receive the ends of said core bars, and means for detachably connecting the adjacent ends oi said Walls.

5. A mold for casting of metal the body of a cellular core for heat exchangers having a plurality of air tubes and a plurality of water channels arranged between adjacent rows of air tubes, said mold comprising a bottom plate adapted to form one side of the cast cellular core, a plurality of core posts for forming said tubes projecting upwardly from said bottom plate and arranged in rows, core bars normally arranged in the lanes between adjacent rows of said posts to form said channels and adapted to be moved lengthwise from the casting, mold walls mounted on said bottom plate around said posts and provided on their inner sides with retaining grooves which receive the ends of said core bars, and means for detachably connecting the adjacent ends of said walls consisting of a locking flange arranged on the end of one of said walls and a hook flange arranged on the end of the adjacent wall and engaging with said locking flange.

6. A mold for casting of metal the body of a cellular core for heat exchangers having a plurality of air tubes and a plurality of water channels arranged between adjacent rows of air tubes, said mold comprising a bottom plate adapted to form one side of the cast cellular core, a plurality of core posts for forming said tubes projecting upwardly from said bottom plate and arranged in rows, core bars normally arranged in the lanes between adjacent rows of said posts to form said channels and adapted to be moved lengthwise from the casting, four mold walls mounted on said bottom plate and forming a rectangular enclosure around said posts and bars, hinges pivotally connecting the lower ends of two walls on two opposite sides of said posts and bars, and means for slidingly connecting the other two of said walls with said hinged walls.

'7. A mold for casting of metal the body of a cellular core for heat exchangers having a plurality of air tubes and a plurality of water channels arranged between adjacent rows of air tubes, said mold comprising a bottom plate adapted to form one side of the cast cellular core, a plurality of core posts for forming said tubes projecting upwardly from said bottom plate and arranged in rows, core bars normally arranged in the lanes between adjacent rows of said posts to form said channels and adapted to be moved lengthwise from the casting, a mold wall mounted on said bottom plate around said posts and bars, and a flooding wall mounted on said bottom plate around said mold wall.

8. A mold for casting of metal the body of a cellular core for a heat exchanger having a plurality of air tubes arranged in longitudinal and transverse rows and a plurality of water channels arranged respectively lengthwise and transversely between the longitudinal and transverse rows of tubes, said mold comprising a bottom plate, a plurality of core posts projecting upwardly from said 'bottom plate, a plurality of transverse core bars arranged respectively in the lanes between adjacent transverse rows of posts. and a plurality of longitudinal core bars arranged respectively in the lanes between adjacent longitudinal rows of posts and intersecting said transverse core bars.

9. A mold for casting of metal the body of a cellular core for a heat exchanger having a plurality of air tubes arranged in longitudinal and transverse rows and a plurality of water chanP nels arranged respectively lengthwise and transversely between the longitudinal and transverse rows of tubes, said mold comprising a bottom plate, a plurality of core posts projecting upwardly from said bottom plate, a plurality of transverse core Ibars arranged respectively in the lanes between adjacent transverse rows of posts and each bar provided with a plurality of slots, and a plurality of longitudinal core bars arranged respectively in the lanes between adjacent longitudinal rows of posts and each longitudinal bar passing through slots of the several transverse bars.

CHARLES A. HAMMOND. 

